package com.mes.interaction.workstation.transfer.handler;
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import com.baomidou.mybatisplus.core.conditions.query.LambdaQueryWrapper;
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import com.mes.device.entity.DeviceConfig;
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import com.mes.device.entity.GlassInfo;
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import com.mes.device.mapper.DeviceGlassInfoMapper;
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import com.mes.device.service.DevicePlcOperationService;
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import com.mes.device.service.GlassInfoService;
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import com.mes.device.vo.DevicePlcVO;
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import com.mes.interaction.workstation.base.WorkstationBaseHandler;
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import com.mes.interaction.workstation.config.WorkstationLogicConfig;
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import com.mes.s7.enhanced.EnhancedS7Serializer;
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import com.mes.s7.provider.S7SerializerProvider;
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import com.mes.service.PlcDynamicDataService;
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import lombok.extern.slf4j.Slf4j;
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import org.springframework.beans.factory.annotation.Autowired;
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import org.springframework.beans.factory.annotation.Qualifier;
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import org.springframework.stereotype.Component;
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import javax.annotation.PreDestroy;
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import java.time.LocalDateTime;
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import java.util.*;
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import java.util.concurrent.*;
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import java.util.concurrent.atomic.AtomicLong;
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import java.util.stream.Collectors;
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/**
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* 卧转立主体设备逻辑处理器
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* 负责玻璃缓冲、容量校验、批次组装、PLC写入等逻辑
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*/
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@Slf4j
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@Component
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public class HorizontalTransferLogicHandler extends WorkstationBaseHandler {
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private final PlcDynamicDataService plcDynamicDataService;
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private final GlassInfoService glassInfoService;
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private final S7SerializerProvider s7SerializerProvider;
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@Autowired(required = false)
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private DeviceGlassInfoMapper glassInfoMapper;
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// 玻璃缓冲队列：deviceId -> 玻璃信息列表
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private final Map<String, List<GlassBufferItem>> glassBuffer = new ConcurrentHashMap<>();
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// 最后扫码时间：deviceId -> 最后扫码时间戳
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private final Map<String, AtomicLong> lastScanTime = new ConcurrentHashMap<>();
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// 监控任务：deviceId -> 监控任务
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private final Map<String, ScheduledFuture<?>> monitorTasks = new ConcurrentHashMap<>();
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// 监控线程池
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private final ScheduledExecutorService monitorExecutor = Executors.newScheduledThreadPool(5, r -> {
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Thread t = new Thread(r, "HorizontalTransferMonitor");
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t.setDaemon(true);
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return t;
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});
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@Autowired
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public HorizontalTransferLogicHandler(DevicePlcOperationService devicePlcOperationService,
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PlcDynamicDataService plcDynamicDataService,
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@Qualifier("deviceGlassInfoService") GlassInfoService glassInfoService,
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S7SerializerProvider s7SerializerProvider) {
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super(devicePlcOperationService);
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this.plcDynamicDataService = plcDynamicDataService;
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this.glassInfoService = glassInfoService;
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this.s7SerializerProvider = s7SerializerProvider;
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}
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@Override
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public String getDeviceType() {
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return DeviceConfig.DeviceType.WORKSTATION_TRANSFER;
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}
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@Override
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protected DevicePlcVO.OperationResult doExecute(DeviceConfig deviceConfig,
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String operation,
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Map<String, Object> params,
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Map<String, Object> logicParams) {
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WorkstationLogicConfig config = parseWorkstationConfig(logicParams);
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try {
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switch (operation) {
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case "checkAndProcess":
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case "process":
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// 这里必须把 params 传进去，以便在多设备任务流程中
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// 能够通过 _taskContext 将卧转立输出的玻璃ID写入任务上下文
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return handleCheckAndProcess(deviceConfig, config, logicParams, params);
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case "startMonitor":
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return handleStartMonitor(deviceConfig, config, logicParams);
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case "stopMonitor":
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return handleStopMonitor(deviceConfig);
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case "clearBuffer":
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return handleClearBuffer(deviceConfig);
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case "clearPlc":
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return handleClearPlc(deviceConfig);
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default:
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return buildResult(deviceConfig, operation, false,
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"不支持的操作: " + operation);
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}
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} catch (Exception e) {
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log.error("卧转立主体处理异常: deviceId={}, operation={}",
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deviceConfig.getId(), operation, e);
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return buildResult(deviceConfig, operation, false,
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"处理异常: " + e.getMessage());
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}
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}
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/**
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* 检查并处理玻璃批次
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* 从数据库读取最近扫码的玻璃，进行容量判断，组装批次，写入PLC
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*/
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private DevicePlcVO.OperationResult handleCheckAndProcess(
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DeviceConfig deviceConfig,
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WorkstationLogicConfig config,
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Map<String, Object> logicParams,
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Map<String, Object> params) {
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String deviceId = deviceConfig.getDeviceId();
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EnhancedS7Serializer serializer = s7SerializerProvider.getSerializer(deviceConfig);
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if (serializer == null) {
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return buildResult(deviceConfig, "checkAndProcess", false,
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"获取PLC序列化器失败");
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}
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try {
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// 1. 从数据库查询最近扫码的玻璃信息（最近1分钟内的记录）
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List<GlassInfo> recentGlasses = queryRecentScannedGlasses(deviceConfig, logicParams);
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boolean hasNewGlass = false;
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if (!recentGlasses.isEmpty()) {
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log.info("查询到最近扫码的玻璃: deviceId={}, count={}",
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deviceId, recentGlasses.size());
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// 2. 更新缓冲队列；仅在有“新玻璃”加入缓冲时才更新最后扫码时间
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hasNewGlass = updateBuffer(deviceId, recentGlasses);
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if (hasNewGlass) {
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lastScanTime
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.computeIfAbsent(deviceId, k -> new AtomicLong())
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.set(System.currentTimeMillis());
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}
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} else {
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log.debug("未查询到最近扫码的玻璃: deviceId={}", deviceId);
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}
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// 3. 检查缓冲队列（即使查询不到新玻璃，缓冲中可能还有待处理的玻璃）
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List<GlassBufferItem> buffer = glassBuffer.get(deviceId);
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if (buffer == null || buffer.isEmpty()) {
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// 缓冲为空且无新玻璃，返回空状态
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return buildResult(deviceConfig, "checkAndProcess", true,
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"缓冲队列为空，无待处理玻璃");
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}
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// 4. 判断是否满足处理条件
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boolean shouldProcess = shouldProcessBatch(deviceId, buffer, config);
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if (!shouldProcess) {
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// 未满足处理条件：构造带有等待进度的提示信息，便于前端展示
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String waitMessage;
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AtomicLong lastTime = lastScanTime.get(deviceId);
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Integer delayMs = config.getTransferDelayMs();
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if (lastTime != null && delayMs != null && delayMs > 0) {
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long elapsedMs = System.currentTimeMillis() - lastTime.get();
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if (elapsedMs < 0) {
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elapsedMs = 0;
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}
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long totalMs = delayMs;
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long elapsedSec = elapsedMs / 1000;
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long totalSec = totalMs / 1000;
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waitMessage = String.format("等待更多玻璃或超时触发批次处理 (已等待 %d/%d 秒)",
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elapsedSec, totalSec);
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} else {
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// 没有有效的最后扫码时间或配置，退回到固定提示
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waitMessage = "等待更多玻璃或30s超时";
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}
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return buildResult(deviceConfig, "checkAndProcess", true, waitMessage);
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}
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// 5. 容量判断和批次组装（考虑玻璃间隙）
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Integer glassGap = getLogicParam(logicParams, "glassGap", 200); // 玻璃之间的物理间隔（mm），默认200mm
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List<GlassInfo> batch = assembleBatch(buffer, config.getVehicleCapacity(), glassGap);
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if (batch.isEmpty()) {
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return buildResult(deviceConfig, "checkAndProcess", false,
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"无法组装有效批次（容量不足）");
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}
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// 6. 写入PLC（尝试从任务参数中获取卧转立编号）
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DevicePlcVO.OperationResult writeResult = writeBatchToPlc(
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deviceConfig, batch, serializer, logicParams, params);
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if (!Boolean.TRUE.equals(writeResult.getSuccess())) {
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return writeResult;
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}
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// 卧转立批次已成功写入PLC，将本批次玻璃ID写入任务上下文，供大车进片使用
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try {
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if (params != null) {
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Object ctxObj = params.get("_taskContext");
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if (ctxObj instanceof com.mes.task.model.TaskExecutionContext) {
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com.mes.task.model.TaskExecutionContext ctx =
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(com.mes.task.model.TaskExecutionContext) ctxObj;
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List<String> batchGlassIds = batch.stream()
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.map(GlassInfo::getGlassId)
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.filter(Objects::nonNull)
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.collect(Collectors.toList());
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if (!batchGlassIds.isEmpty()) {
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ctx.getSharedData().put("transferReadyGlassIds",
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new java.util.ArrayList<>(batchGlassIds));
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log.info("卧转立已输出批次玻璃到任务上下文: deviceId={}, glassIds={}",
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deviceConfig.getId(), batchGlassIds);
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}
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}
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}
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} catch (Exception e) {
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log.warn("卧转立写入任务上下文transferReadyGlassIds失败: deviceId={}", deviceConfig.getId(), e);
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}
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// 7. 从缓冲队列中移除已处理的玻璃并更新状态
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removeProcessedGlasses(deviceId, batch);
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glassInfoService.updateGlassStatus(
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batch.stream().map(GlassInfo::getGlassId).collect(Collectors.toList()),
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GlassInfo.Status.PROCESSED);
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// 8. 检查缓冲是否为空，如果为空且无新玻璃，标记为完成
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List<GlassBufferItem> remainingBuffer = glassBuffer.get(deviceId);
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boolean bufferEmpty = remainingBuffer == null || remainingBuffer.isEmpty();
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boolean noNewGlass = !hasNewGlass;
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String msg;
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if (bufferEmpty && noNewGlass) {
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// 缓冲已清空且无新玻璃，任务完成
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msg = String.format("批次已写入PLC: glassCount=%d, glassIds=%s, 缓冲已清空，任务完成",
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batch.size(),
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batch.stream().map(GlassInfo::getGlassId).collect(Collectors.joining(",")));
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} else {
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// 缓冲还有玻璃或可能有新玻璃，继续运行
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msg = String.format("批次已写入PLC: glassCount=%d, glassIds=%s",
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batch.size(),
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batch.stream().map(GlassInfo::getGlassId).collect(Collectors.joining(",")));
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}
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return buildResult(deviceConfig, "checkAndProcess", true, msg);
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} catch (Exception e) {
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log.error("检查并处理玻璃批次异常: deviceId={}", deviceId, e);
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return buildResult(deviceConfig, "checkAndProcess", false,
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"处理异常: " + e.getMessage());
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}
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}
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/**
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* 查询最近扫码的玻璃信息
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*/
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private List<GlassInfo> queryRecentScannedGlasses(
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DeviceConfig deviceConfig,
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Map<String, Object> logicParams) {
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if (glassInfoMapper == null) {
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log.warn("GlassInfoMapper未注入，无法查询最近扫码的玻璃");
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return Collections.emptyList();
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}
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try {
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// 从配置中获取workLine，用于过滤（配置中是Integer类型）
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Integer workLine = getLogicParam(logicParams, "workLine", null);
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// 查询state=1的玻璃记录（已扫码交互完成，等待卧转立处理）
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LambdaQueryWrapper<GlassInfo> wrapper = new LambdaQueryWrapper<>();
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wrapper.in(GlassInfo::getStatus, GlassInfo.Status.PENDING, GlassInfo.Status.ACTIVE)
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.eq(GlassInfo::getState, 1) // 只查询state=1的玻璃（已扫码完成）
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.orderByDesc(GlassInfo::getCreatedTime)
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.last("LIMIT 20"); // 限制查询数量，避免过多
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// 如果配置了workLine，则过滤work_line字段
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if (workLine != null) {
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wrapper.eq(GlassInfo::getWorkLine, workLine);
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}
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List<GlassInfo> recentGlasses = glassInfoMapper.selectList(wrapper);
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log.debug("查询到最近扫码的玻璃: deviceId={}, workLine={}, count={}",
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deviceConfig.getId(), workLine, recentGlasses.size());
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return recentGlasses;
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} catch (Exception e) {
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log.error("查询最近扫码的玻璃信息异常: deviceId={}",
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deviceConfig.getId(), e);
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return Collections.emptyList();
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}
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}
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/**
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* 更新缓冲队列
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* @return 是否有新的玻璃被加入缓冲（用于判断是否刷新 lastScanTime）
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*/
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private boolean updateBuffer(String deviceId, List<GlassInfo> newGlasses) {
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List<GlassBufferItem> buffer = glassBuffer.computeIfAbsent(
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deviceId, k -> new CopyOnWriteArrayList<>());
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Set<String> existingIds = buffer.stream()
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.map(item -> item.glassInfo.getGlassId())
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.collect(Collectors.toSet());
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boolean hasNewGlass = false;
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for (GlassInfo glass : newGlasses) {
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if (!existingIds.contains(glass.getGlassId())) {
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buffer.add(new GlassBufferItem(glass, System.currentTimeMillis()));
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hasNewGlass = true;
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log.debug("添加玻璃到缓冲队列: deviceId={}, glassId={}",
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deviceId, glass.getGlassId());
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}
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}
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return hasNewGlass;
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}
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/**
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* 判断是否应该处理批次
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* 注意：这里只做粗略判断，精确的容量计算（含间隙）在assembleBatch中完成
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*/
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private boolean shouldProcessBatch(String deviceId,
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List<GlassBufferItem> buffer,
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WorkstationLogicConfig config) {
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// 条件1：缓冲队列已满（达到容量限制）
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// 粗略计算：所有玻璃长度之和（不考虑间隙，因为间隙是动态的）
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int totalLength = buffer.stream()
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.mapToInt(item -> item.glassInfo.getGlassLength() != null ?
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item.glassInfo.getGlassLength() : 0)
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.sum();
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// 粗略判断：如果总长度接近容量（留一些余量给间隙），就触发处理
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// 精确判断会在assembleBatch中完成
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if (totalLength >= config.getVehicleCapacity() * 0.8) { // 80%阈值，留余量给间隙
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log.info("缓冲队列容量接近满载，触发批次处理: deviceId={}, totalLength={}, capacity={}",
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deviceId, totalLength, config.getVehicleCapacity());
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return true;
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}
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// 条件2：30s内无新玻璃扫码
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AtomicLong lastTime = lastScanTime.get(deviceId);
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if (lastTime != null) {
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long elapsed = System.currentTimeMillis() - lastTime.get();
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if (elapsed >= config.getTransferDelayMs()) {
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log.info("30s内无新玻璃扫码，触发批次处理: deviceId={}, elapsed={}ms",
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deviceId, elapsed);
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return true;
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}
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}
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return false;
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}
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/**
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* 组装批次（容量判断，考虑玻璃间隙）
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* @param buffer 缓冲队列
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* @param vehicleCapacity 车辆容量（mm）
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* @param glassGap 玻璃之间的物理间隔（mm），默认200mm
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* @return 组装好的批次列表
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*/
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private List<GlassInfo> assembleBatch(List<GlassBufferItem> buffer,
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int vehicleCapacity,
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int glassGap) {
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List<GlassInfo> batch = new ArrayList<>();
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int usedLength = 0;
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int gap = Math.max(glassGap, 0); // 确保间隔不为负数
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for (GlassBufferItem item : buffer) {
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GlassInfo glass = item.glassInfo;
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int glassLength = glass.getGlassLength() != null ?
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glass.getGlassLength() : 0;
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if (glassLength <= 0) {
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continue; // 跳过无效长度的玻璃
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}
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if (batch.isEmpty()) {
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// 第一块玻璃，不需要间隙
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if (glassLength <= vehicleCapacity && batch.size() < 6) {
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batch.add(glass);
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usedLength = glassLength;
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} else {
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break; // 第一块就装不下
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}
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} else {
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// 后续玻璃需要考虑间隙：玻璃长度 + 间隙
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int requiredLength = glassLength + gap;
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if (usedLength + requiredLength <= vehicleCapacity && batch.size() < 6) {
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batch.add(glass);
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usedLength += requiredLength; // 包含间隙
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} else {
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break; // 装不下了
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}
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}
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}
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log.debug("批次组装完成: batchSize={}, usedLength={}, capacity={}, glassGap={}",
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batch.size(), usedLength, vehicleCapacity, gap);
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return batch;
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}
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/**
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* 写入批次到PLC
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*/
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private DevicePlcVO.OperationResult writeBatchToPlc(
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DeviceConfig deviceConfig,
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List<GlassInfo> batch,
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EnhancedS7Serializer serializer,
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Map<String, Object> logicParams,
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Map<String, Object> params) {
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Map<String, Object> payload = new HashMap<>();
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// 写入玻璃ID（最多6个）
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int count = Math.min(batch.size(), 6);
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for (int i = 0; i < count; i++) {
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String fieldName = "plcGlassId" + (i + 1);
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payload.put(fieldName, batch.get(i).getGlassId());
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}
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// 写入玻璃数量
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payload.put("plcGlassCount", count);
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// 写入卧转立编号（优先从任务参数获取，其次从设备配置获取，直接写入编号，不进行位置映射）
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Object inPosition = null;
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if (params != null) {
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try {
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Object ctxObj = params.get("_taskContext");
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if (ctxObj instanceof com.mes.task.model.TaskExecutionContext) {
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com.mes.task.model.TaskExecutionContext ctx =
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(com.mes.task.model.TaskExecutionContext) ctxObj;
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inPosition = ctx.getParameters().getExtra() != null
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? ctx.getParameters().getExtra().get("inPosition") : null;
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}
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} catch (Exception e) {
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log.debug("从任务参数获取卧转立编号失败: deviceId={}", deviceConfig.getId(), e);
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}
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}
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// 如果任务参数中没有，从设备配置中获取
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if (inPosition == null) {
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inPosition = getLogicParam(logicParams, "inPosition", null);
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}
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if (inPosition != null) {
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// 直接写入编号本身，不进行位置映射转换
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payload.put("inPosition", inPosition);
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log.info("写入卧转立编号: deviceId={}, inPosition={}", deviceConfig.getId(), inPosition);
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} else {
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log.debug("未配置卧转立编号，跳过写入: deviceId={}", deviceConfig.getId());
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}
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// 写入请求字（触发大车）
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payload.put("plcRequest", 1);
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try {
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plcDynamicDataService.writePlcData(deviceConfig, payload, serializer);
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log.info("批次已写入PLC: deviceId={}, glassCount={}, inPosition={}",
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deviceConfig.getId(), count, inPosition);
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return buildResult(deviceConfig, "writeBatchToPlc", true,
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"批次写入成功");
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} catch (Exception e) {
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log.error("写入批次到PLC失败: deviceId={}", deviceConfig.getId(), e);
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return buildResult(deviceConfig, "writeBatchToPlc", false,
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"写入失败: " + e.getMessage());
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}
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}
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/**
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* 从缓冲队列移除已处理的玻璃
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*/
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private void removeProcessedGlasses(String deviceId, List<GlassInfo> processed) {
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List<GlassBufferItem> buffer = glassBuffer.get(deviceId);
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if (buffer == null) {
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return;
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}
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Set<String> processedIds = processed.stream()
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.map(GlassInfo::getGlassId)
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.collect(Collectors.toSet());
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buffer.removeIf(item -> processedIds.contains(item.glassInfo.getGlassId()));
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}
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/**
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* 启动监控任务（定期检查并处理）
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*/
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private DevicePlcVO.OperationResult handleStartMonitor(
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DeviceConfig deviceConfig,
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WorkstationLogicConfig config,
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Map<String, Object> logicParams) {
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String deviceId = deviceConfig.getDeviceId();
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// 停止旧的监控任务
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handleStopMonitor(deviceConfig);
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// 获取监控间隔
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Integer monitorIntervalMs = getLogicParam(logicParams, "monitorIntervalMs",
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config.getScanIntervalMs());
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// 启动监控任务
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ScheduledFuture<?> future = monitorExecutor.scheduleWithFixedDelay(() -> {
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try {
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// 监控任务不在多设备任务上下文中运行，这里不需要传入 params/_taskContext
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handleCheckAndProcess(deviceConfig, config, logicParams, null);
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} catch (Exception e) {
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log.error("监控任务执行异常: deviceId={}", deviceId, e);
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}
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}, monitorIntervalMs, monitorIntervalMs, TimeUnit.MILLISECONDS);
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monitorTasks.put(deviceId, future);
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log.info("已启动卧转立监控任务: deviceId={}, interval={}ms",
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deviceId, monitorIntervalMs);
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return buildResult(deviceConfig, "startMonitor", true,
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"监控任务已启动");
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}
|
|
/**
|
* 停止监控任务
|
*/
|
private DevicePlcVO.OperationResult handleStopMonitor(DeviceConfig deviceConfig) {
|
String deviceId = deviceConfig.getDeviceId();
|
ScheduledFuture<?> future = monitorTasks.remove(deviceId);
|
if (future != null && !future.isCancelled()) {
|
future.cancel(false);
|
log.info("已停止卧转立监控任务: deviceId={}", deviceId);
|
}
|
return buildResult(deviceConfig, "stopMonitor", true, "监控任务已停止");
|
}
|
|
/**
|
* 清空缓冲队列
|
*/
|
private DevicePlcVO.OperationResult handleClearBuffer(DeviceConfig deviceConfig) {
|
String deviceId = deviceConfig.getDeviceId();
|
glassBuffer.remove(deviceId);
|
lastScanTime.remove(deviceId);
|
log.info("已清空缓冲队列: deviceId={}", deviceId);
|
return buildResult(deviceConfig, "clearBuffer", true, "缓冲队列已清空");
|
}
|
|
/**
|
* 清空PLC相关字段（供测试页面一键清空使用）
|
*/
|
private DevicePlcVO.OperationResult handleClearPlc(DeviceConfig deviceConfig) {
|
try {
|
EnhancedS7Serializer serializer = s7SerializerProvider.getSerializer(deviceConfig);
|
if (serializer == null) {
|
return buildResult(deviceConfig, "clearPlc", false, "获取PLC序列化器失败");
|
}
|
|
Map<String, Object> payload = new HashMap<>();
|
// 根据卧转立主体写入的字段进行清空
|
for (int i = 1; i <= 6; i++) {
|
payload.put("plcGlassId" + i, "");
|
}
|
payload.put("plcGlassCount", 0);
|
payload.put("plcRequest", 0);
|
payload.put("inPosition", 0);
|
|
plcDynamicDataService.writePlcData(deviceConfig, payload, serializer);
|
log.info("卧转立主体清空PLC字段完成: deviceId={}", deviceConfig.getId());
|
return buildResult(deviceConfig, "clearPlc", true, "已清空卧转立主体PLC字段");
|
} catch (Exception e) {
|
log.error("卧转立主体清空PLC失败: deviceId={}", deviceConfig.getId(), e);
|
return buildResult(deviceConfig, "clearPlc", false, "清空PLC失败: " + e.getMessage());
|
}
|
}
|
|
/**
|
* 构建操作结果
|
*/
|
private DevicePlcVO.OperationResult buildResult(DeviceConfig deviceConfig,
|
String operation,
|
boolean success,
|
String message) {
|
return DevicePlcVO.OperationResult.builder()
|
.deviceId(deviceConfig.getId())
|
.deviceName(deviceConfig.getDeviceName())
|
.deviceCode(deviceConfig.getDeviceCode())
|
.projectId(deviceConfig.getProjectId() != null ?
|
String.valueOf(deviceConfig.getProjectId()) : null)
|
.operation(operation)
|
.success(success)
|
.message(message)
|
.timestamp(LocalDateTime.now())
|
.build();
|
}
|
|
/**
|
* 应用关闭时清理资源
|
*/
|
@PreDestroy
|
public void destroy() {
|
log.info("正在关闭卧转立监控线程池...");
|
|
// 停止所有监控任务
|
for (String deviceId : new ArrayList<>(monitorTasks.keySet())) {
|
ScheduledFuture<?> future = monitorTasks.remove(deviceId);
|
if (future != null && !future.isCancelled()) {
|
future.cancel(false);
|
}
|
}
|
|
// 关闭线程池
|
monitorExecutor.shutdown();
|
try {
|
if (!monitorExecutor.awaitTermination(5, TimeUnit.SECONDS)) {
|
monitorExecutor.shutdownNow();
|
if (!monitorExecutor.awaitTermination(5, TimeUnit.SECONDS)) {
|
log.warn("卧转立监控线程池未能正常关闭");
|
}
|
}
|
} catch (InterruptedException e) {
|
monitorExecutor.shutdownNow();
|
Thread.currentThread().interrupt();
|
}
|
|
log.info("卧转立监控线程池已关闭");
|
}
|
|
/**
|
* 玻璃缓冲项
|
*/
|
private static class GlassBufferItem {
|
final GlassInfo glassInfo;
|
final long timestamp;
|
|
GlassBufferItem(GlassInfo glassInfo, long timestamp) {
|
this.glassInfo = glassInfo;
|
this.timestamp = timestamp;
|
}
|
}
|
}
|
